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WELCOME TO

TRAINING PROGRAMME ON

‘MATERIAL HANDLING’ DURING 

17TH – 18TH DECEMBER, 2013  AT

SAIL / CET , RANCHION

BY B.K.BISOYI

MANAGER (MECH.)SAIL/CET, RANCHI

INTRODUCTION

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THE TECHNOLOGY OF CRUSHING

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Crushing is the reduction of large rocks into smaller rocks by

Impact

Attrition

Shear

Compression

THE TECHNOLOGY OF CRUSHING

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When a material is compressed/sheared/attrition, it will break from the weakest zone.

Weakest zones

What is a Crusher ?

A crusher is a machine designed to reduce large rocks into smaller rocks by compression/attrition/shear/impact.

CLASSIFICATION OF CRUSHERS(BASED ON TYPE OF CRUSHING)

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COMPRESSIVE CRUSHERS IMPACT CRUSHERS (Compress the material until it breaks) (Principle of quick impact to crush the material)

JAW CRUSHERS IMPACTORS

CONE CRUSHERS HAMMER MILLS

GYRATORY CRUSHERS

ROLLER CRUSHERS

CRUSHERS

CLASSIFICATION OF CRUSHERS (BASED ON SIZE OF CRUSHING)

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TERTIARY/ FINE CRUSHERS

CRUSHERS

QUATERNARY / FINE

CRUSHERS

JAW CRUSHERS

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Mainly used as primary crushers

Produce materials that can be transported by belt conveyors to the next crushing stage.

Capacity: Upto 1600 tphPrinciple of operation:

The crushing process takes place between a fixed jaw and a moving jaw

Intermittent process

Hydraulic setting adjustment

Liner platesManganese steel, Ni-cr alloyed CI

JAW CRUSHER IS A RELIABLE, ROBUST EQUIPMENT AND IS QUITE POPULAR IN PRIMARY CRUSHING APPLICATIONS.

BETTER RETURN ON INVESTMENT.

MAJOR COMPONENTS OF JAW CRUSHERS

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TYPES OF JAW CRUSHERS

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SINGLE TOGGLE JAW CRUSHER DOUBLE TOGGLE JAW CRUSHER

JAW CRUSHER AT KIOM

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Capacity : 600 tphFeed opening : 1520 mmPlate Width : 2130 mm

CONE CRUSHERS

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Principle of operation:The material is crushed in a crushing cavity between an external fixed element(bowl liner) and internal moving element (mantle) mounted on the oscillating shaft assembly.

An eccentric shaft rotated by a gear and pinion produces the oscillating movement of the main shaft.

The fragmentation of materials results from the continuous compression that takes place between the mantle liners and bowl liners in the chamber.

Mainly used as intermediate or fine crushing to obtain a product with good uniform shape

Capacity: Upto 1200 tph

BOWL WITH LINER

MANTLE WITH LINER

CSSOSS

CONE CRUSHERS Contd…

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Adjustment of OSS/CSS:

The settings can be adjusted by

Rotating the bowl against the threads so that the vertical position of the outer wear part is changed.

•Time consuming but uniform wear & tear of liners

By lifting and lowering the main shaft

•Adjustment can be done continuously under load.

Principle of operation:

The eccentricity causes the cone head to oscillate between OSS and CSS discharge opening.

The eccentricity is one of the major factors which determine the capacity of the cone crushers.

Higher capacity in secondary crushing with

low operating cost

CONE CRUSHERS - MAJOR COMPONENETS

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TERTIARY CONE CRUSHER OF M/s HEC FOR MIOM – VARIOUS COMPONENTS UNDER MFG.

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MAIN FRAME

PINION

RING GEAR

DRIVE SHAFT

Capacity 500 tphFeed Size: (+)30 to (-)75 mmOutput: 30 mm

TERTIARY CONE CRUSHERS OF M/s HEC FOR MIOM – VARIOUS COMPONENTS UNDER MFG.

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ECCENTRIC SHAFT HOUSING

ADJUSTMENT RING ASSEMBLY

GEAR ASSEMBLY

CONE CONE

MAIN SHAFT

CROSS SECTION OF A CONE CRUSHER

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Metso Cone Crusher H P VXKI.mpg

GYRATORY CRUSHERS

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Efficient primary crushing in mining application.

Crushing chamber designed to accept feed materials of relatively larger size.

Capacity: 100 tph-9000tph

Principle of operation:

Same as cone crusher.

Provides much larger feed area than a jaw crusher

Taller, heavier with massive foundation

Adjustment of closed side settings(CSS):

Equipped with a hydraulic setting adjustment, which adjust CSS and thus have better productivity.

GYRATORY CRUSHERS - MAJOR COMPONENTS

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GYRATORY CRUSHING STATION

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GYRATORY CRUSHER STATIONS

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Mobile Primary Gyratory Station

CRUSHER - SUPPLIERS

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METSO FL SMITH SANDVIK THYSSENKRUP

ROLLER CRUSHERS

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Purpose:Mainly for crushing easily fractured materials such as soft limestone, chalk and clay.

Reduction ratio - 3:1 to 5:1

Principle of operation:The roller crushers consists of two rollers. One of the roller shafts is adjustable while the other has a fixed position and is provided with a flywheel.

The gap between the two rollers can be varied depending upon the degree of crushing required.

Rollers have scrapers to remove any material sticking to the surface.

IMPACT CRUSHERS

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Purpose Generation of fine materials e.g. Sand.Liberate hard minerals from waste materialsHigh reduction ratio and cube shaped product.Capacity: Upto 1800tph

Principle of operationThe feed material is crushed in the quick rotational movement of hammers/bars fixed to the rotor .

The particles produced are then further crushed inside the crusher as they collide against crusher parts and against each other, producing a finer, better-shaped product.

HAMMERS/ BARS

HIGHER CAPACITY, CUBICAL PRODUCT & GENERATION OF

FINES IS NOT A PROBLEM

NOT RECOMMENDED FOR CRUSHING TOO FINES MATERIALS

IMPACT CRUSHERS - MAJOR COMPONENTS

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IMPACT CRUSHERS - TYPES

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HORIZONTAL SHAFT IMPACTOR

VERTICAL SHAFT IMPACTOR

TWIN ROTOR IMPACTOR

VERTICAL SHAFT IMPACT CRUSHER

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Vertical shaft impactor

The vertical shaft impactor is like a “stone pump” which operates like a centrifugal pump.

The material is fed through the center of the rotor, where it is accelerated to high speed before being discharged through the openings in the rotor periphery.

The material is crushed as it hits on the outer body and also due to the rock-on-rock action.

Used for generation of fines e.g. Sand, gravel etc. VERTICAL SHAFT

IMPACTOR

HAMMER MILLS

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PurposeTo grind and pulverise materials that are not too hard or abrasive.

Principle of operation:

Similar to impactors

The hammer mill rotor has many pivoted hammers attached to it and the discharge opening consists of a grate through which the material has to pass, thus contributing to the reduction process.

The rotor speed and the grate spacing can be optimised to suit different applications.

REDUCTION RATIO OF CRUSHERS - TYPICAL CALCULATION

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REDUCTION RATIO OF CRUSHERS - GRAPHICAL REPRESENTATION

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How to select a Crusher?

FACTORS AFFECTING THE SELECTION OF CRUSHERS

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Purpose of crushing (Primary / Secondary / Tertiary / Quaternary)

Location (Fixed /Mobile)

Type of material (Hard /Soft/Medium)

Abrasiveness (Abrasive/Non Abrasive)

Feed size of materials (Larger/Smaller/Medium)

Capacity of crusher (Higher /Medium / Lower)

Reduction ratio (Higher /Medium / Lower)

Product Size (Fines /Coarse)

Operation & Maintenance aspects

Other Economic aspects

SELECTION OF CRUSHERS (Based on Capacity)

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SELECTION OF CRUSHERS (Based on Capacity, Feed Size & End product)

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Crusher type

Typical Process Stage

Feed Size upto (mm)

Typical maximum

End Product size (mm)

Reduction Ratio

Typical Capacity

(tph)

Amount of Fines

Produced

Hardness of material

Abrasiveness

Moisture content Application

Jaw crushers

Primary 1400 200-300 3:1 to 5:1 Upto 1600 Low Soft to very hard

HighDry to slightly wet, not sticky

Heavy mining

Gyratory crushers

Primary 1500 200-300 4:1 to 7:1 > 1200 LowSoft to

very hardHigh

Dry to slightly wet, not sticky

Heavy mining

Cone crushers

Secondary 450 60-80 3:1 to 5:1 Upto 1200 Low

Medium hard to

very hard

Low /High

Dry or wet, not sticky

Mining, Quarried

materials, Sand & gravel

Tertiary / Quaternary

300 0-30 3:1 to 5:1 Upto 1000 Low / Medium

Horizontal shaft

impactors

Primary / secondary

1300 200-300 10:1 to 25:1

Upto 1800 Medium / High Soft to

medium hard

LowDry or wet, not

sticky

Quarried materials, sand

& gravel, recycling

Vertical shaft

impactors

Tertiary 40 0-30 6:1 to 8:1 Upto 600 HighMedium hard to

very hardLow

Dry or wet, not sticky

Sand & gravel, recycling

Roller Crusher

Primary Fines Fines 3:1 to 5:1 Upto 500 HighSoft Low Dry or wet

crushing of easily fractured

materials

SELECTION OF CRUSHERS

COMPARISION OF TYPES OF CRUSHERS

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Characteristics Jaw crusher Gyratory crusher Cone Crusher

Type Primary Crushing Primary CrushingSecondary / Tertiary /

QuaternaryCapacity Lesser

(≤ 1600 tph)

Higher

(1000-9000 tph)

Medium

(≤ 1200 tph)

Work Intermittently Continuously Continuously

Reduction Ratio 3:1 to 5:1 4:1 to 7:13:1 to 5:1

Weight of Equipment Medium Heavy Medium

Crushing Surface Jaw Platescrushing surface flares in

from top to bottomcrushing surface flares in

from bottom to top

Feed OpeningLarger /Medium feed

openingLarger feed opening Smaller feed opening

Principle of operation

Compression Gyration Gyration

Operating Cost Medium High Economical

Relative merits/demerits

Chances of passage of material without

crushing

No chance of passage of material without crushing

No chance of passage of material without crushing

CRUSHER – SPECIFIC POWER CONSUMPTION (TYPICAL)

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Type of crusher Specific Power Consumption (kWhr/t)

Gyratory Crusher 0.1 to 0.2

Jaw Crusher 0.4 to 0.6

Cone Crusher 0.4 to 0.6

Impactor Crusher 1 to 1.2

CRUSHER - SPECIFICATION

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Sl. No. Description Specification

1 TYPE OF CRUSHER JAW / GYRATORY /CONE

2 Quantity (No.) 1

3 Rated Capacity (tph) 1000

4 Design Capacity (tph) 1300

5 ROM Dimensions(mm x mm x mm)

1200x1000x1000

6 Material to be handled Direct Ore and Beneficiable ore

7 Crusher Feed F100 (mm) 1000

8 Crusher Feed F80 (mm) 600

9 Crusher Product P100 (mm) 288

10 Crusher Product P80 (mm) 134

11 Bulk Density (t/m3) 2.2

12 Crushing Work Index (kWh/t) 11

CRUSHER - PERFORMANCE

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The performance of a crusher depends upon the right choice & correct operation of associated equipments such as feeders, conveyors, screens, drives, silos etc.

CLOSED LOOP CRUSHER CIRCUIT

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OPEN LOOP CRUSHER CIRCUIT

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THANK YOU

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